Note: Descriptions are shown in the official language in which they were submitted.
û~18
~ACKGROU~D OF TH~ INVENTI~ ¦
This invantion r~lates to a. knitted fabric panel
structure and to a proces~ of manufacture of the structure.
U.~. patent 3,4~1,427 discloses a threa-dimensional
woven ~iberglass fabric impregnated with resin to create a
rigid structural panel having intermediate spaced apart walls
o ribbed cores forming dsad air cavities. Because the woven
structure tcnds to readily sag after resin hardening backup
~tructure must be ~nserted in the cavities. This, however,
results in a quite e~pensive production.
Re~in-hardened fiber compounds have gained widespread
use as structural panels or as sound absorbing elements. Such
panels are used in aircraft structure bacause of their light
weight, ma~imum rigidity and resistance to compression
characterist~cs.
Weaves such as waft velvet and warp velvet may be used~
in wea~ing the three-dimen~ional panel For economical¦
production a double layer panel is made in the form of a
so-callea double velvet ~n which the pile threads used as
connectlng rib~ between the layer-forming ~elour threads form a
double layer. The length of the floating threads is adjustab~e
so that various rib lengths can be effect0d. The pile threads
are then cut between their ends on a cutting bench.
SUM~A~Y OF TM~ INVENTION
It 18 therefore an objact o~ the present invention to
provide a light weight, multi-layered panel structure of simple
an~ economical con~truction yet highly efective and capable of
~j being man actured using available techniques and equipment and¦
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which has a high 1nterna1 restoring force and following
hardening has high internal stability. yet requires relatively
little resin.
Specifically, the knitted fabric panel structure
according to the i~vention has ~irst and second spaced apart
knitted layers and an intermediate spacing knit of ribs
interconnecting the layer~. The ribs of the spacing knit are
of an industrial yarn such as aramide fiber, carbon fiber,
ceramic fibar, fiber glass or combinations of such fibers. The
panel is impregnated with a hardensd resin such that the
intermediate ribs form rigid spacing elements of the first and
second lay~rs.
The lntermediate ribs have a mean length greater than
the spacing between the layers, are angularly disposed relative
to the first'and second layers, and are curved between opposite
ends thereof. The ribs may be curved continuously in the same
dirsction, and the rib~ are mutually spaced apart and may
comprise twi~ted individual strands.
The knitted fabric panel structure of the invantion has
high rigidity an~ resistance to compression while being of
light weight. The distance between the layers is not bridged
by woven wall sections but rather by free float~ng threàd
bridges which serv~ to braca the layers. Due to the
combination of a knitted structurs and the property of the ribs
of the spacing unit, the rib-forming supports have a restoring
force which i8 released tending to straighteh out the ribs.
The ribs brace the two layers apart at a short spacing. The
6tructurs, which iB knitted using known techniques, can
tolerate use without any reorientation in the interlacing areas
-~3253'~
with the layers. The abundance of loops of corresponding
knitted fabrics offers a high fl~ible region of transition
between th~ knitted layer~ and the intermediate ribs.
The knitted fabric panel structure of the invention is
also capable of being ormed into a curved or spherical
structure without developing radial folds which are otherwise
present in structures with flat surfaces. Because of the
amount of thread used during the knitting process the
distribution i~ almost di~tortion-free. The restoring force or
stored energy of the intermediate ribs eliminates the need for
any asternal backup structure.
When hardensd with resin knitted fabric creates out o
the many unevenly distributed, individual, free-standing
~ntermediate ribs, such stable spacing elements that even the
masimum load~ dur~ng use of the panel structure can be absorbed
without damage. In addition, a high degree of sound proofing
or sound ab~orption i8 effectsd from the high number of
cavities formed in the present ~tructure.
Anothar commercially advantageous feature of the present
structur~ i~ that the mean length of the intermediate ribs are
great~r than the distance between the layers. Thus, t~e
intermsdiate ribs have at least partially a rat~er steèp
angular disposition such that the lead applied along the
entirety of the panel effacts an equidirectional component of
layar displacement. This is primarily beneficial for partial
peak load~ since then the entire structure acts as a unit to
resist deformation.
The unidirectional attitude of the ribs facilitates
determining the daflection of the ribs. And, the panel having
L~ 3 ~ 8
angled intermediate ribs can be formed with a slight ¦
curvature. Stress along the a~is o~ ths intermediate ribs
efects deflsction avoiding mutual friction between the ribs.
The intermedia~e ribs are cont:inuously curved in thel
same direction, The unidiractional curving provides equal¦
zones of elasticity over the entire length of the intermediatel
rib. The orientation of the ribs is such that they have a¦
vertical, column-like transitional region. The slight tilt¦
attitude of the ribs in addition to their continuous
unidirectional cuxvature effects the desired high restoring
force of the panel structure. To ~void bulding when the ribs¦
are subjected to compressive stresses, the ribs may be formed !
of slightly twisted ind~vidual ribs. Such an array of ribs
provides a large number of multiple, local spring loadings.
And, even greater distancRs between the first and second spaced
layers of th~ panel structure can b~ bridged without~
compromising the ~tability. ~he slight twis~ing of the ribs
spaces tha individual ribs ~part.
In accordance with the present precess the first and
second layers are knitted and spaced a predetermined distance
apart by e~tending an intermediate spacing unit of ri~s
therebetween for lnterconnecting the layers d~ring the
knitting. The ribs of ths spacing unit ara of an industrial¦
yarn having a restoring force such as aramide fiber, carbon¦
fiber, ceramic fiber, fiberglass, or a blend of such fibers.
The ribs of the spacing unit are impregn~ted with a resin, and
a squeezing or compression force is applied to tha layers for
removing e~cess resln from the spacing knit, the ribs being
dlstorte~ ~uring thls force applying step. The squeezing or
compression force is removed for releasing the restorin~ force
L ~ . U
of tha ribs, and the spacing unit is allowed to harden for
forming the ribs as a rlgid spacing element between the layers.
, I
BRI~D DE~IP~ION OF ~E~ 9E
Figure 1 iB B top plan view of the knitted fabric panel
structure according to the ~nvention;
Figure 2 i~ a front side elevational view of the panel
structure viewed in the direction o arrow A in Figure l;
Figure 3 i8 an ~nd alevational viaw of a panel structure
~imilar to that of Figure 1 but having a curved central
section, and viewed in a ~lrection of arrow B of Figure l;
F~gure 4 i8 an enlarg~d schematic view of Figure 2;
Figur~ 5 i8 an enlarged schematic view of Figure 3 but
without the curved central portion; and
Figur~ 6 is a perspsctive view illustrating in cube
outline a representative arrangement of the individual, twisted
ribs of the intermediate spacing knit between the outer layers
o~ the structure of Figures 1-4.
DETAIL~ ~E~CRIPTION QF THE INVE~TION
Panal ~tructure 1 of the invention is formed on ~a
knitting mac~ine a8 a multi-layered structure havin7 a first,
upper knitted layer 2 and a second~ bvttom ~nitted layer 3.
The panel ~tructure i8 formed using conventional knitting
technology ~uch as that used to manuacture velour.
An intermediate spacing knit of ribs 4 is formed during
the knitting operation a~ having thread sections uniformly
distribute~ throughout the pan~l. Intermediate ribs 4
interconnect the layers in spaced apart relationship. Panel
`: ~ ~ 3~
structure l compri~es a knitted fabric in which the upper and
lower layer~ an~ the intermediate ribs are intergrally joined
forming a double velvet enmeshed structura.
The number of supporting threads or ribs 4 is a function
of the knit density, such that by changing the number of thread
ribs a greater or fewer number of intermediate ribs 4 can be
generated continuously compared to that illustrated in the
drawings. --
Intermediate ribs 4 of the knitted structure areoriented substantially perpendicularly to parallel 13yers 2 and
3 ~o as to effect a highly elastic, relatively movable enmeshed
fabric bed. Thus, if a portion of the knitted fabric which is
not yet imprsg~ate~ with resin is deformad, the rib sections
can take over the compensating rib len~ths from the highly
looped snmeshed ~tructure, or may be inserted into the knitted
structure. Of course, this compensation relates to a portion
of the rib length so that in the basic fabric the desired
parallsl relationship of the layers 2 and 3 is retsined even
when imposing a curved or spherica} deformation to the basic
fabric. The knitted fabric contracts more at the concave inner
surface of the curvature such that the e~ternal conve~ surfa~a
of th~ curved layers is taken up from a given loop supply.
The knitted fabric panel structure of the invention is
made of ~nau~trial yarn such as aramide fiber, carbon fiber,
ceramic fiber, glas~ fibar or various blends of these fibers.
Such fibers have an inherent restoring forca after being
sub~ected to compre~sive forces applied to layers 2 and 3. As
a result of this restoring force inherent in such high
performance fibers and also due to the connecting structure,
1 u ~ 3 1 8
I the supporting threads forming intermediate ribs 4 have a I
tendency to restore themsRlves to an unstressed condition upon ¦
the removal of such compressive forces. This results in a ¦
parallel spacing of layers 2 snd 3 illustrated by the spacing x
between the layers in Figure 4 which corresponds to several
layers of thlckness. I
The intermediate spacing knit ol. ribs 4 as well as the
remainder of th~ knitted structure is stiffaned by impregnating
the fibers with hardened resin so that ~ntermediate ribs 4
betwean the fir~t and second layers ~ and 3 form rigid spacing
elements. After the fibers are resin impregnatea the e~cess
resin is squeezQd out by applying a compressive force to the¦
layers. The spontaneous repositioning or restoring of the
intermediate ribs to their~positions shown in Figures 4 and 5
occurs even' after the panal structure has been completely
compressed. Correspondingly, during knitting no damage is
incurred as a consequ6nce of the requisite redirecting and
leoping.
As ~llustrated $n Flgures 4, 5 and 6, the ~mean lenqth~
of each of intermediate ribs 4 i8 greater than spacing
between layers 2 and 3. The free supporting thread sections
forming rib~ 4 ~o not change on the shortest path b~tween the
two ad~acent parallal lay~rs 2 and 3. Rather, as shown ln the
drawing~, the ribs havs a slight tilt as seen in Figure 5. All
the interme~iate riba have a unidirectional tilt form~ng a tilt
angle o~ appro~imately 60 ~o the plane of the panel. The
intermedlate rib~ est0nd ln rows ~nd in succession ~o that the
ribs are mutually spaced apart as shown at 5 in Figures 5 and 6.
The knit profile of the panel can ~e seen when viewed in
-~ .~ a~8 1l
the diraction of arrow A (Fig. 4) such that intermediate ribs 4
are each in the form of a continuous unidirectional curve.
Thuæ, the true or mean length of each rib is greater than
spacing x.
The term ~mean length~ is ~elected because each of the
intermediate ribs 4 comprise a f~mlly o~ curved, tilted
individual ribs 4~, 4~, 4~', 4~' which are illustrated for
only one of the ribs 4 in Fiqures 4 and 5 for the sake o
clarity. The tilt and curvature of the ribs are
unidirectional. In an imaginery e~tension of the ribs, the
curvature and th~ tilt th~reof result in a nearly spiral-shape
o the individual rib~ 4', 4'', 4''', 4'''' of the intermediate
ribs 4. Th~ individual ribs traverse the spacing between
layers 2 and 3 without makin~ substantial contact with one
another. Correspondingly the individual ribs serYe as
individually ~tanding spring elements. To avoid bulges, the
yarns comprising filaments ar~ Islightly twisted to form the
indivldual ribs.
The individual ribs ara together oriented at thair ends
terminating in layers 2 and 3 to form an anyle of
appro~imately 4S relative to a line of orientation L-L sho~n
in Figure 6. The spacial distribution of the termin~l regions
from top to bottom can be readily seen as provided in Figure 6
by the orientation aid in the form of a cube. Accordingly, at
the bottom, on the right, the individual ribs 4' and 4'' lie
substanti~lly along line L-l., and the individual rib 4''' lies
somewhat at right angles in the lateral vicini~y of individual
rib 4''. Otherwise, individu~- rib 4'''', lying at a greater
~: ~' ' ,, ~ ~ , ,t ~ 1~
distance from ribs 4~ to 4~ is arranged at the intersectson
of the diam~trals of ~he bottom face of- the cube. Tilted at an
angle the upper ends of the individual ribs terminate in the
upper face of tha c~be, although in the other half of the
cube. At the upper face of the cube individual rlb~ 4''' and
4'''' lie along line L-L, snd individual rib 4'' i~ located at~
its upper root end adjacent ~ndividual rib 4''' inwardly of
the cube such that individual rib 4' i8 locate~ centrally
between opposite sides of the cube at the upper face.
The region of the cube of the adjacent intermediate rib
4 toward the sight line B is merely indicated by circles at the
bottom face of the cube, in the interest of clarlty. Both
}ines L-L at the top and bottom faces of th~ cube li2 parallel
to the sight lin~ ~.
The column-like transitional regions of intermediate rib
4 are located relative to a ~ertical plana of a reference line
~-E in such a manner that ad~acent upper ends of the ribs
~lightly o~erlap one anothsr a~ ~een in Fig. 5. In Figur~ 4, a
plane E-~ plotted in a correaponding direction, illustrates
that ad~acent ribs ~o not overlap in thi~ direction. Rather,
th~ ribs taporinq into the upper and lower layers 2 and 3 lIe
in common plan~ E-E, and the middle section of a~ adjac2nt¦
arched rib lying to the left of plane E-E i~ tangent to this¦
plane.
The ends of the individual ribs 4' to 4~''' at layers 2
and 3 can have column like material accumulations of synthetic¦
resin orming stumps (not shown) which are somewhat comparable¦
to the underground roots of trees. The result is an almostl
truncaded conical transition between the interior of layers 2'
~ ~ 1 ., ~ û 3 !i 8
and 3 an~ the spacing elements. The truncaded conical base
corresponds to the multiple of th~ cross-section of an ¦
individual rib 4' or 4'' or 4''' or 4''''. Despite the ¦
clearances 5 between intermediate ribs 4 and the clearances
among tha individual ribs in each of the clusters of ribs 4 the
result is always a highly rigid, column-like spacing body that ¦
nevertheless e~hihits some flexibility even in the stretch
direction o~ the individual ribs.
Partial loads applied to panel 1 also brings the
intermediate ribs lying in the outer areas of the panel into
play, since as a consequence of the slight and unidirectional
tilt, lay~rs 2 and 3 shift in opposite directions upon the
application of compressive forces against the layers. This
provide3 good load distribution, and the aforedescribed
orientat~ons an~ ~hapes of intermediate ribs 4 also serve to
d~æsapate orces.
The aforedescribed knitted panel structure is
impregnated with commercially availabla resin plus a hardener..
E~cess resin is squeezed or rolled out so that the internal
structure is resin-ree s~cept for the wetted, rib forming
supporting threads and the two impregnated layers of fabric
The corre~pond~ng evacuation of resin to form, a large
percentag~ of ca~ities occurs to an e~tent that the restoring
force of intermeaiate ribs 4 is released after the removal of
the compressive squeeze forces until the ribs resume their
initial rela~ed positions. Alternatively, vacuum pressure can
be applied for removinq the excess resin until the
r~sin-hardener reaction and does not remove until just before¦
the flnal haraening. The structure that had been compressed upi
to that interval then rights itself -~p a~gal~n. With, for
e~ample two layers and corresponding-ly precise and uniform ¦
application of the resin, it i~ not necessary to remo~e the
e~cess resin content by ~gueezing or rolling. Following the
drawing process, the hardoned components are riyid and
resistant to compression. The deformability can be controlled
by correspondlng layering such as fringe fabric, knitted
fabric, satin or cloth, or by means or deep drawing. Thus, the
corresponding improved formability of the spacing knit
facilitate~ to a sign~ficant degree tha manufacture of
spherical or curved panels. Such a spherical shape is
illustrated in Figure 3, although other shapes not illustrated
can also be formed.
The sandwich-like construction of the presant knitted¦
fabric panel' counteracts any tendency to delaminate due to its'
single coheslv~ structur~.
Obviously, many other modifications and variations of
the present invention ~re made possible in the light of the
above teachings. It i~ therefore to be understood that within
the scope of the appended claims the invention may be practiced
othorw~s han ar specifica1ly deRcribed.
